Method and apparatus for forming loom beam



May 6, 1969 M. M. BRYAN, ..u=av 3,441,991

METHOD AND APPARATUS FOR FORMING LOOM BEAM Ofiginal Filed Jan. 1 1966Sheet of 6 FIG] INVENT OR MORRIS M. BRYAN,JR.

May 6, 1969 r M. MJBRYAN. JR ,4 1 9 METHOD AND APPARATUS FOR FORMING1400M BEAM Original Filed'Jan. 18, 19 66 Sheefi of 6 INVENTOR FIGSATTORNEYS May 6, 1969 M. M. BRYAN, JR 3,

METHOD AND APPARATUS FOR FORMING LOOM BEAM Original Filed Jan. 18, 1966Sheet 3 of 6 May 6, 1969 iginal Filed Jan. 18, 1966 M. M.. BRYAN. JR3,441,991

METHOD AND APPARATUS FOR FORMING LOOM BEAM Sheet M. M. BRYAN. JR

.rP /L 7 //M iv in May 6, 1969 METHOD AND APPARATUS FOR FORMING LOOMBEAM Original Filed Jan. l8, 196s ATTORNEYS May 6, 19 69 OriginalFiledJan. 18; 1966 Sheet 6 of 6 INVENTOR MORRIS u. BRYAN, JR

United States Patent 3,441,991 METHOD AND APPARATUS FOR FORMING LOOMBEAM Morris M. Bryan, Jr., Jefferson, Ga., assignor to The JeffersonMills, Inc., Jefferson, Ga., a corporation of Georgia Originalapplication Jan. 18, 1966, Ser. No. 521,369, now Patent No. 3,321,153,dated May 23, 1967. Divided and this application Nov. 3, 1966, Ser. No.591,804

Int. Cl. D03j 1/02; D02g 3/36, 1/16 US. Cl. 2828 11 Claims ABSTRACT OFTHE DISCLOSURE Apparatus for forming a loom beam directly fromindividual yarn packages, including the combination of a creelcomprising a plurality of mobile creel trucks movable into a stationarycreel frame, means for withdrawing the yarns from the creel, means forapplying sizing to the yarns, means for drying the yarns, and means forwinding the yarns onto a spool to form the loom beam. The mobile creeltrucks are constructed to support a plurality of yarn packages in upwardand lateral rows, and include guide means movable into facingrelationship with each yarn package to guide the yarn from the yarnpackage toward the side of the mobile creel truck. A second set of yarnguides are positioned on each side of the creel truck, at one end of thecreel truck, to collect the yarns of lateral rows of yarn packagestogether as a group of yarns. The stationary creel frame includes yarnguides for collecting the groups of yarns of adjacent trucks.

This application is a division of copending application Ser. No.521,369, filed Jan. 18, 1966 now US. Patent 3,321,153, granted May 23,1967.

The present invention relates to a method and apparatus for forming aloom beam. More particularly, the present invention relates to a methodand apparatus for continuously withdrawing a plurality of yarns from theindividual packages mounted within a creel, arranging the yarns inparallel side-by-side relationship, applying a sizing material to theyarn, drying the yarns, and winding the yarns directly onto a largespool to form a loom beam.

Heretofore, loom beams have generally been formed in a series ofrepetitious steps. A relatively small number of yams were withdrawn andparallelized from individual yarn packages mounted within a small creel.After parallelization, the yarns were wound upon an intermediate spoolto form a section beam. The yarns from several of these section beamswere then combined into a single sheet of warp yarns and sized.Subsequent to the sizing operation the yarns were wound upon a largespool to form the loom beam.

While the formation of the intermediate section beams appears to be anundesirable and inefiicient middle step in the formation of loom beamsit has previously been necessary in order to keep the size of the creeldown to a practical limit wherein it may be easily and eflicientlyloaded and threaded with the individual yarn packages. Additionally, asomewhat complicated apparatus to combine the yarns from the sectionbeams was required.

It should be understood that a loom beam of the type under discussionwill generally contain 2400 to 3200 warp yarns while the section beamsmay range from about 400 to 700 warp yarns. These figures are notintended to be at all-inclusive but will serve to point out the relativesizes of the beams and indicate the increased problems which may beexpected in forming loom beams as opposed to section beams.

"ice

The present invention provides a method and apparatus whereby a loombeam may be formed directly as the yarns are withdrawn from theirindividual packages thereby dispensing with the necessity of formingintermediate section beams. Generally, this is accomplished by providinga novel creel in combination with a sizing apparatus and novel dryingapparatus in forming the loom beams. The creel is capable of greatversatility being easily and efficiently loaded with individual yarnpackages as well as readily varied in size depending upon the number ofyarns desired in the ultimate loom beam. Upon being withdrawn from thecreel, the individual yarn ends are parallelized and formed into a warpsheet which is passed through a sizing bath. Upon being thoroughlywetted with the sizing material the warp sheet is conducted through anovel combination heated chamberheated drum drying mechanism whereafterit may be wound directly onto a large spool to form the loom beam.

The various features and advantages of the present invention will becomereadily apparent from the following description and the accompanyingdrawings in which:

FIG. 1 is a side elevational view of the complete system of the presentinvention for forming loom beams;

FIG. 2 is a top plan view of the system shown in FIG. 1;

FIG. 3 is an enlarged top plan view of one embodiment of section of thepresent invention.

FIG. 4 is a partial front elevational view of the, creel as seen alongline 44 in FIG. 3;

FIG. 5 is a side elevational view of a creel truck which forms a portionof the creel of the present invention;

FIG. 6 is a cross-sectional view of a creel truck taken along line 6-6in FIG. 5;

FIG. 7 is an enlarged perspective view showing the yarn guide-bar thatis used on the creel truck;

FIG. 8 is an enlarged perspective view showing the yarn guide-bar usedon the stationary creel frame of the present invention;

FIG. 9 is a transverse cross-sectional view of the drying mechanism;

FIG. 10 is an enlarged cross-sectional view of one of the drying drumsin the drying mechanism.

Referring first to FIG. 1, the overall system of the present inventionis illustrated wherein a large number of warp yarns 11 (i.e. 2400) arecontinuously withdrawn from a creel 10. This creel will be describedlater in fur ther detail. The warp yarns 11 are passed through atensioning device 12 and comb 13, both of which are Well known in theart, whereupon the Warp yarns are parallelized and placed undersubstantially constant tension.

From the tensioner and comb the parallelized warp yarns are led into asizing application 14 wherein they are initially formed into a Warpsheet by a first roll pair 15. The sizing material is applied to thesheet of warp yarns while in the applicator usin g emersion or spraytechniques. Any excess sizing material is removed from the warp sheet asit passes between a pair of squeeze rolls 16 on leaving the sizingapplicator,

Since the sizing material oftentimes contains volatile solvents ordispersing materials it may be advantageous to provide a hood 17 abovethe sizing applicator to withdraw any vapors, and reclaim the materialby conventional condensation techniques.

After the sizing material has been applied, the solvents must be removedby conducting the warp sheet through a drying mechanism 18. Thismechanism provides a first drying path wherein the sheet is subjected toheated air currents within a series of interconnected chambers.Thereafter, the warp sheet is led in a tortuous path around a series ofheated drums. The particular construction of the drying mechanism willbe described in greater detail later.

Air may be circulated through the drying mechanism by providing anexhaust fan for withdrawing the solvent loaded air and circulating it toa condensation recovery system. The hood 17 over the sizing applicatormay also be efficiently tied-in with this system.

The fully dried warp sheet is immediately led to a conventional windingmechanism 19 on leaving the drying mechanism. At the winding mechanismthe warp sheet is Wound onto a large spool 19' to form the loom beam.

The novel creel of the present invention, as shown in FIGS. 3 and 4,comprises a stationary frame 20 into which a plurality of creel trucks30 may be assembled. The sta tionary frame 20 is divided into a seriesof longitudinally arranged compartments 21, two series of suchlongitudinally arranged compartments being illustrated in FIG. 3. Eachof the compartments 21 is of such a size as to be able to receive asingle creel truck. To aid in receiving the creel trucks in thecompartments the frame 20 has a set of guide tracks 22 associated witheach longitudinal series of compartments. These tracks are fixedlysecured to the same substrate to which the frame is secured.

Each compartment of the stationary frame has a pair of guide frames 23positioned on opposite sides of its forward or front portion. As shownin detail in FIG. 4, the guide frames comprise vertical supports 24between which a series of vertically spaced horizontal guide bars 25 aresecured. The spacing of these guide bars generally corresponds to thespacing of similar guide bars on the creel trucks which will be apparentfrom the following description.

As an alternative to the above described construction the guide bars 25may be merely cantilevered from a single vertical support 24 rather thansecured between a pair of such supports. This alternative embodiment isillustrated in FIGS. 3 and 7.

The construction of the guide bars 25 is the same regardless of whichmeans of support is employed. As shown in FIG. 7, a series of guidehooks 26 extend from the upper side of the bar. It is intended that oneguide hook be provided for each warp yarn passing over the guide bar. Asmooth rod 27 is mounted adjacent the base of the guide hooks over whichthe warp yarns may slide without snagging or breaking.

The guide bars 24 of each compartment progressively increase in lengthand number of guide hooks from the rear to the front of the creel sincean additional group of warp yarns are picked up from the creel trucks 30in successive compartments. This is generally illustrated on thestationary frame 20 in FIG. 3 in progressing from the left side to theright side.

It should be understood that the stationary frame may contain fewer ormore compartments than illustrated and that these compartments may beemployed either as a single series or as multiple series. The ultimatearrangement employed will depend upon the desired flexibility of thecreel.

The creel trucks 30 are thus illustrated in FIGS. 46. Each of thesecreel trucks is capable of supporting a predetermined number ofindividual yarn packages. Furthermore, each truck is constructed so asto allow the individual yarn ends to be withdrawn from the packages andled in an orderly arrangement to the guide frames 23 of the compartmentin which the creel truck is positioned.

Each creel truck comprises a base frame 31 which is mounted on aplurality of wheels 32 for movement. Extending from the underside of thebase frame are a pair of projecting guide members 33. These guidemembers engage the sides of the tracks 22 whereby the creel trucks maybe guided into and positioned within the compartments 21 of thestationary frame. The construction of the guide members 33 may vary fromrigid lugs to rotatable casters depending upon the desired refinement ofthe truck construction.

Mounted longitudinally and centrally of the base frame 31 is a verticalframework having a series of vertical supporting strips 34. Projectingfrom the opposite faces of each support strip and in a symmetricalmanner are a series of vertically spaced spindles 35 upon whichindividual yarn packages 36 may be mounted. As shown in FIG. 4 thespindles 35 are angled slightly upward so as to prevent the yarn package36 from slipping off the end as the yarn is withdrawn from the package.

On the opposite lateral sides of the creel truck there are a series ofvertical guide strips 37 which are positioned in line with the spindlesupport strips 34. These guide strips are pivotally mounted at theirupper ends on horizontal support 38 and at their lower end on the baseframe 31. The pivotal mounting allows the guide strips to be pivotedoutward so that individual yarn packages 36 may be mounted on thespindles 35. Each of the vertical guide strips 37 has a plurality ofguide holes 39 which correspond in number and position with the spindles35. It is through these guide holes that the yarn ends are withdrawnfrom the individual yarn packages.

On the front of each creel truck at opposite sides are two guide racks.Each guide rack comprises a pair of vertical supporting rods 40 and 41between which a series of vertically spaced horizontal guide bars 42 areadjustably secured. There is provided one guide bar for each horizontalrow of spindles 35. These guide bars are of similar construction to theguide bars 25 previously described. Shown in detail in FIG. 8, they havea plurality of guide hooks 43 extending from the upper surface. Oneguide hook is provided for each spindle in the horizontal row. Again, asmooth horizontal bar 44 is provided near the base of the guide hooks 43to prevent the yarns from snagging and breaking on the surface of theguide bar 42.

While there are two hundred spindles per creel truck as shown in thedrawings it should be understood that this number may vary andfurthermore that all the spindles on each truck need not necessarilyhave yarn packages mounted thereon to enable the truck to be used inframe 20.

In setting up a creel truck, the guide strips 37 are first pivotedoutward to allow the individual yarn packages 36 to be placed on thespindles 35. After mounting the yarn packages the guide strips arepivoted back to their normal positions and the individual yarn ends areled through the guide holes 39. The yarn ends from the individualpackages within each horizontal row are then led separately through theguide hooks 43 of the corresponding guide bar mounted on the front ofeach truck. When all of the desired yarn packages have been mounted andthe yarn ends threaded through their corresponding guide means the creeltruck is ready to be positioned within one of the compartments 21 of thestationary frame 20.

While the creel truck is being moved into position within the stationaryframe 20 it is desirable to releasably secure the threaded yarn ends inposition to prevent the necessity of rethreading any yarns which becomepulled out during transit. Satisfactory results have been obtained byplacing a strip of wire cloth adjacent each guide bar 42. Once the yarnshave been threaded through the guide hooks 43 they may be held in placeby merely pushing the yarn ends down onto the wire cloth. Of course,other suitable means for accomplishing the same results may also be usedand will be apparent to those skilled in the art.

The individual creel trucks 30 are then rolled into position Within thestationary frame 20 while being conveniently guided by tracks 22. Sinceseveral longitudinally aligned creel trucks are positioned within thestationary frame at the same time it may be desirable to provide thetrucks with a coupling means (not shown). A variety of such couplingmeans are well known in the art and therefore description becomesunnecessary. As a result, a plurality of the creel trucks may beconveniently coupled together and rolled into position as a group withinthe stationary frame.

Once the individual creel trucks are assembled within the compartmentsof the stationary frame the yarn ends from each creel truck are threadedthrough the hooks 26 on the corresponding guide bars 25 of thestationary frame. The yarn ends of the creel trucks located behind thelead truck are led through successive guide bars 25 until they reach thefront of the creel. This is more easily understood by reference to FIG.3 wherein the guide bars are shown to increase in length from left toright as additional warp yarns are picked up from successive creeltrucks.

The creel described above is capable of easy loading and threading toprovide suflicient warp yarns for forming loom beams of various sizeswithout the necessity of forming intermediate section beams.

From the front of the creel all the yarns from the individual packagesmounted on the creel trucks are led in orderly fashion to the tensionerand comb for subsequent formation into a warp sheet.

As shown in FIGS. 1 and 2 the warp sheet is passed through aconventional sizing applicator. The sizing provides a temporaryprotective coating for the yarns while they are processed into a wovenfabric. Thereafter, the sizing is removed from the yarns, usually bywashing in water.

Various types of sizings may be employed depending upon the particularyarn. Natural or chemically modified starches in conjunction withlubricants are used in cotton and rayon; gelatin is applied to wool,rayon and acetate yarns. Water soluble polyacrylic acid, polyvinylalcohol and copolymers of styrene and maleic acid are applied to nylon,acetate and other synthetics.

After the sizing material has been applied to the warp yarns the sheetis dried as it is conducted through a drying mechanism 18. This dryingmechanism is shown in greater detail in FIGS. 9 and 10. The warp sheet,identified by numeral 50, is conducted through the drying mechanism inthe direction indicated by the arrows.

The drying mechanism 18 comprises a first elongated, up-right chamber 60which communicates at its upper end with a horizontal duct 65. Thishorizontal duct, in turn, communicates with the upper end of a secondup-right chamber 61 which is somewhat shorter in length then the firstup-right chamber. Surrounding both the first and the second up-rightchambers 60 and 61 are continuous thicknesses of insulation 63. Mountedwithin the insulation and adjacent the side walls of these chambers area plurality of individual heaters 62 of a conventional type.

Thus, it should be apparent that the air within chambers 60 and 61 willbecome heated and tend to rise thereby indirectly heating the duct 65.Fresh air gains admittance to the chambers through the openings in thebottom.

The wet warp sheet 50 is guided through these heating chambers by aseries of rolls. As the heated air within the chambers becomes saturatedduring the drying process it is withdrawn through the top of horizontalduct 65 by means of an exhaust fan (not shown). As indicated previouslyan exhaust hood for the sizing applicator may be tied into thishorizontal duct.

Rapid drying of the warp sheet is obtained due to thecontinuous'circulation of heated dry air through the chambers 60 and 61and into duct 65 by way of the exhaust fan. However, due to the speed atwhich the warp sheet travels through these drying chambers completedrying may not always be obtained. Therefore, as the warp sheet 50emerges from the heating chamber 61 it is led in a tortuous path arounda series of heated drums 70, all of which are of similar construction.As is evident from FIG. 9, the tortuous path of the warp sheet allowsmore contact time between the sheet and the drum surface. Upon leavingthe final heating drum the warp sheet is completely dry and ready to bewound upon the spool 19' to form the loom beam.

Each drying drum 70 comprises a cylindrical shell 71 having oppositespoke type end plates 72 and 73 to which are secured correspondinghollow axle stubs 74 and 75. These axle stubs are mounted for rotationin stationary supports 76 and 77 by means of bearings 78 and 79. Thestationary supports may be suitably mounted on the drying mechanismframework.

A plurality of stationary gas heaters 80 are positioned within thedrying drum 66 to heat the cylindrical shell as the drum rotates. Theseheaters are adjustably mounted in spaced-apart in-line relationship onthe shaft 81. The ends of shaft 81 extend through the hollow centers ofthe axle stubs 74 and 75 and are fixedly secured in stationary arms 82and 83. These arms may be conveniently clamped to the drum supports 76and 77. Shaft 81 does not rotate with the drying drum but may beprovided with a capability of being rotatably adjusted.

As illustrated in FIGS. 9 and 10 the individual heaters 80 are of thegas type although it should be understood that other types may also beemployed. With the gas type heater, a supply of gas may be delivered bypipe 84 to the vicinity of one of the axle stubs of the drying drum 70.Individual gas conduits 85 connect each heater 80 with the supply pipe84. These conduits are positioned adjacent the shaft 81 and pass throughthe hollow center of the corresponding axle stub.

The line of individual heaters are positioned within each drying drum 70in such a manner as to heat that portion of the rotating cylindricalshell immediately before the warp sheet 50' contacts the shell. This isbest illustrated with the three drying drums in FIG. 9. In this mannervery little heat is lost from the drum prior to contacting the warpsheet and efficient drying is obtained.

The temperatures employed within the drying mechanism may vary as thewarp sheet passes therethrough, but at no time should it be so high asto cause possible scorching or damage to the warp yarns. Thistemperature may also vary according to the particular type of yarn beingdried some being capable of withstanding higher temperatures thanothers. Adequate control of the temperatures may be obtained through theuse of suitable thermostats.

I claim:

1. An apparatus for forming a loom beam comprising:

(A) a creel for supplying a plurality of warp yarns,

said creel including:

(1) a stationary frame having one end from which a plurality of warpyarns are withdrawn, said frame having a plurality of stationary yarnguides for assisting the withdrawal of said warp yarns,

(2) a plurality of movable creel trucks associated with said stationaryframe, each of said creel trucks comprising;

(a) a base mounted on a plurality of wheels,

(b) at least one support extending upward from said base and having aplurality of spindles for mounting individual yarn packages,

(c) a first set of yarn guides arranged adjacent said spindles forinitially receiving and guiding said warp yarns axially outward fromsaid yarn packages, and

(d) a second set of yarn guides fixedly positioned on one end of saidcreel truck for receiving and guiding said warp yarns from said firstset of yarn guides,

(3) and means for positioning said creel trucks within said stationaryframe whereby said warp yarns can be led from said second set of yarnguides to said stationary yarn guides,

(B) means for withdrawing said warp yarns from said stationary yarnguides of said creel,

7 (C) means for arranging said warp yarns into substantially planarside-by-side relationship as they are withdrawn from said creel,

(D) means for applying a sizing to said arranged warp yarns,

'( E) means for drying said sized warp yarns,

(F) and means for winding said warp yarns onto a spool to form a loombeam.

2. The invention according to claim 1 wherein said stationary frame ofsaid creel comprises at least one series of longitudinally alignedcompartments and a stationary yarn guide is mounted adjacent eachcompartment.

3. The invention according to claim 2 wherein each stationary yarn guidecomprises a longitudinal bar having a plurality of aligned guide hooksextending outward therefrom and means to prevent snagging of said warpyarns as they pass through said guide hooks..

4. The invention according to claim 1 wherein said first set of yarnguides forming a part of each creel truck comprises at least one guidestrip extending upward from said base, said guide strip having aplurality of apertures positioned to correspond with said spindles forreceiving therethrough said warp yarn from said yarn packages mounted onsaid spindles.

5. The invention according to claim 4 wherein said spindles are arrangedon opposite sides of said support and aligned in upwardly extendingrows, each row being provided with a corresponding guide strip, eachguide strip being pivotally mounted whereby it may be pivoted away fromsaid spindles to permit replacement of said yarn packages.

6. The invention according to claim 5 wherein said spindles are alsoaranged in substantially horizonitafl aligned rows and said second setof yarn guides comprises a series of guide bars, each guide barcorresponding to one of said horizontally aligned rows and having aplurality of upwardly extending guide hooks.

7. The invention according to claim 6 wherein said guide bars areprovided with means for temporarily securing the yarn ends of said warpyarns after they have been threaded through said first and second setsof yarn guides.

8. The invention according to claim 1 wherein said means for drying thesized warp yarns includes at least one rotatable drying roll arranged tocontact the warp yarns with its peripheral surface through a limitedregion of its path of rotation, said drying roll comprising an outercylindrical shell mounted for rotation having a plurality of individualheating means mounted adjacent its internal surface, said heating meansbeing fixedly mounted with respect to the rotating peripheral surface ofthe shell along a line parallel to the axis of the shell and in advanceof said limied region.

9. The invention according to claim 8 wherein the heating means areadjustable along a line parallel to the axis of the shell.

10. Apparatus for forming a loom beam directly from a plurality of yarnpackages comprising in combination:

a creel for supporting a plurality of yarn packages,

said creel including a plurality of mobile creel trucks each comprisinga plurality of spindles arranged in upward and lateral rows on oppositesides of the trucks and angled from the vertical and each spindle beingpositioned to support a yarn package, first yarn guide means movable toa position adjacent and substantially in axial alignment with eachspindle for guiding the yarn away from each yarn package and to the sideof the truck, second yarn guide means positioned at one end of each ofsaid creel trucks and arranged to collect together the yarns from theyarn packages of each lateral row of yarn packages, a stationary creelframe defining a centralopening for receiving a line of said mobilecreel trucks and including a plurality of yarn guide means on each sidethereof at intervals along the length thereof corresponding to thelength of said creel trucks for receiving the yarns from said secondyarn guide means of said creel trucks, means for withdrawing the yarnsfrom said creel and arranging the yarns into a substantially planarsideby-side relationship, means for applying sizing to the yarns, meansfor drying the yarns, and means for winding the yarns onto a spool toform a loom beam.

11. A method of forming a loom beam comprising:

placing a plurality of yarn packages on a plurality of mobile platformsin upward and lateral rows on opposite sides of the platforms,

withdrawing the yarn from each yarn package first in a direction towardthe sides of the mobile platform and then collecting together the yarnsof the laeral rows of the yarn packages in upwardly spaced groups ofyarn at one end of the mobile platform,

moving a plurality of the mobile platforms into alignment with oneanother adjacent a stationary yarn guide apparatus,

extending the yarns of each group of yarns from the mobile platforms asa group through the stationary yarn guide apparatus,

combining each group of yarns of a lateral row of yarn packages of eachmobile platform with groups of yarns of corresponding lateral rows ofyarn packages of the other mobile platforms in the stationary yarn guideapparatus,

extending the combined groups of yarns into a substantially side-by-sideplanar relationship,

applying sizing to the yarns, drying the yarns, and winding the yarnsonto a spool.

References Cited UNITED STATES PATENTS LOUIS K. RIMRODT, PrimaryExaminer.

US. Cl. X.R.

